Transcript Technical Options for Foam Sector

ODS/GHG Reduction: Options in Foams
February 2011
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Forces: commercializing new molecule(s)
Environmental regulation or restriction . . . .
• EU F-Gas Directive: restricts the use of materials with GWP > 150 in
emissive applications
– Restricts the use of HFC-134a in specific applications
– EU one component foam industry regulation: 04 July 2008
– EU novelty aerosol industry regulation: 04 July 2009
• Kyoto Protocol: Developed countries reduce GHG emissions 5% (1990)
– EU reduce GHG emissions by 8% (1990 levels)
– Japan striving to meet Kyoto commitments
• Industry concern with further GWP regulation
• Taxation of raw materials basis GWP values
– Economic impact on finished goods
• Climate Change bills in U.S. Congress
• Globally: reduction in ODS and climate change
Environmental regulation is now driving commercialization
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Fluorine Products – a History of Innovation
Markets Served: Mobile and Stationary Air conditioning, Refrigeration, Insulation
Foam for Buildings and Electrical Appliances, Cleaning Solvents, Nuclear Power,
Aerosols, Heat Pumps, Geothermal and Solar Renewables
MONTREAL PROTOCOL
CFC
Phase-out
CFCs
1900s
HCFCs
1990s
Ozone Depleting
and Very High Global
Warming Potential
EU LEGISLATION
F-Gas Regulation
HCFC
Phase-out
HFCs
2000s
HFOs
2010s
Non-Ozone Depleting
but has High Global
Warming Potential
Low-Global-Warming
Potentials and No Ozone
Depletion Effect
Innovation Tied to Environmental Compliance
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Montreal Protocol calls for HCFC-141b phase out
• Montreal Protocol on Substances that Deplete the Ozone Layer
Baseline average of 2009 and 2010
Freeze 2013
Reductions: 10%m : 2015 > 35% :2020 > 67.5% : 2025 > 2.5% per year reduction 2030 to 2040
Complete phase out 2040
• HCFC-141b has been phased out in United States, Japan and Europe
– HCFC transitioned the industries to environmentally improved materials
• Global pressure may accelerate the phase out date in other countries
– example: India and UAE, as well as others
• HFC’s are utilised where key needs demanded are:
– insulation performance, and energy efficiency of finished products (refrigerators)
– non-flammability property
• Hydrocarbons, and other non-HFC materials, while flammable, may be used:
– where deficiencies in insulation performance and flammability can be tolerated
– spray foam industry is particularly sensitive to flammability (application / equipment)
HCFC’s successfully phased out in many countries
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Blowing Agent Attributes
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Phase out of ozone depleting substances: ODS
Global warming potential: climate change impact reduction
Ground level smog formation: limited contribution
Low order of toxicity – safety in manufacturing use and finished products
Non-flammable – safety in manufacturing use
Insulation performance / energy efficiency: low lambda or k-factor
Processing and equipment implications
– Liquids: appliance (refrigerators); commercial refrigeration; spray foam; insulating panels
– Gases: extruded polystyrene (thermoplastics); special applications
• Compatible with formulations and processing equipment materials
– Low conversion cost: equipment investment and reformulation
• Economic valuation in use – translates into finished product economics
• Commercially available on a global basis
Attributes support governments’ and industry’s preferences
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What is HFC 245fa?
India: February 2011
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HBA-2: Liquid Low GWP Blowing Agent
Environmental Properties
• Low global warming potential: GWP100 = 7
• Non-flammable: ASTM E-681
• Volatile Organic Compound: very low MIR
500
HBA-2
c-C5
Vapor Pressure (kPa)
Fluorochemical
• Liquid blowing agent
• Molecular weight: less than HFC-245fa
HFC-245fa
0
0
Temperature ( oC)
75
Toxicity Screening
• Preliminary stages: Results are very promising
• Assessments completed:
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Cardiac Sensitization
Genetic Testing: Ames Assay & Mouse Micronucleus
Acute Inhalation (Rat)
Inhalation: 2 & 4 week
Unscheduled DNA Synthesis
Honeywell HBA-2 Blowing Agent promising low GWP molecule
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HFC-245fa & HBA-2 Insulation Applications
• Household refrigerators (appliances)
• Commercial refrigeration
– food preservation
• Building construction (residential and
commercial)
– Sprayed foams
– Roofing and sheathing (board stock)
– Panels (faced panels, sandwich panels)
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HFO-1234ze(E) Blowing Agent
Hydrofluoroolefin (HFO)
trans – 1,3,3,3 – tetrafluoropropene
• CHF = CHCF3
• Molecular Weight: 114
• Gas: TBP = -19 °C (- 3 °F)
• MIRHFO-1234zeE < MIREthane
Vapor Pressure
1600
HFC-134a
1400
Pressure (KPa)
Environmental Properties
• Zero ozone depletion potential (ODP)
• Low global warming potential: GWP100 = 6
• Non-flammable: U.S. Department of Transportation
– “Non-flammable Compressed Gas”
– No flame limits by ASTM E681
– “Non-flammable”: EU Test Method A11
• Volatile Organic Compound Measure
– Maximum Incremental Reactivity
HFO-1234zeE
1200
1000
800
600
400
200
0
0
10
20
30
40
50
60
o
Temperature ( C)
Non-ODS / Low GWP / Non-Flammable / Low POCP
= Environmentally Sustainable Molecule =
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HFO-1234ze(E) Insulation Applications
• Extruded thermoplastics foams
– Extruded polystyrene
• One component foams
– Sealing around doors and windows
– Repairing damage
– Adhesives
• Two component ‘pressurized’ foams
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Transition Strategy: Timeframe Dependent
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HFC-245fa ‘Bridge’
ODS Reduction
Environmental Compliance
HCFC-141b Blends
Low Capital Investment
Non-Flammable
HCFC-141b
Appliance
Panels
Spray Foam
2010
2011
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2012
2013
HBA-2
ODS Reduction
GWP = 7
Non-Flammable
Low Capital Investment
2014
2015
• HFC-245fa: Commercially available today – a transition solution
– Widely utilised in NA. Specific applications: EU / Japan / China
– HFC/HCFC-141b blend technology: ‘reduced cost’ transition option
• HBA-2: World-scale capacity target is mid-decade
– Conversion to HFC-245fa ‘directly applicable’ to HBA-2
HFC-245fa: Low capital, medium term safe route to ODS management
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Blowing Agent Energy Efficiency (Lambda)
Lambda: mW/m- o K at 24 o C
Blowing Agent Comparative PUR Lambda
21.0
20.0
20.0
19.6
19.0
18.2
18.0
17.0
HCFC-141b
HFC-245fa
HBA-2
• Lambda is the measure of heat transfer through a material in a given time and temperature
• Lower lambda is better: significant energy efficiency driven by insulation characteristics
• When compared to HCFC-141b insulation performance:
– HFC-245fa is equal to slightly better
– HBA-2 has shown improvement over HFC-245fa
– HFC-245fa/HCFC-141b blends should exhibit similar insulation performance
Transitioning: HCFC-141b  HFC-245fa  HBA-2 maintains energy efficiency
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Sprayed Foam Comparison: HFC-245fa & HBA-2
25.0
24.0
Thermal Conductivity (mW/n K)
Thermal Conductivity (mW/nK)
25.0
Low water formulation
23.0
HFC-245fa
22.0
21.0
20.0
HBA-2
19.0
18.0
17.0
16.0
HFC-245fa
24.0
High water formulation
23.0
22.0
HBA-2
21.0
20.0
19.0
18.0
17.0
16.0
4
9
14
19
24
29
34
39
44
4
14
Mean Temperature, °C
Spray Foam Properties
Physical Properties
Blowing Agent
Density, kg/m3 (pcf)
Dimensional stability, vol %
Hot (90 °C)
Hot Humid (70°C, 95RH)
Cold (-29 °C)
Compressive Strength, kPa (psi ) @
10%
Parallel
Perpendicular
% Closed Cell Content
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Low Water Content
HFC-245fa
HBA-2
32.2(2.01)
29.6 (1.85)
24
34
Mean Temperature, °C
44
High Water Content
HFC-245fa
HBA-2
35.7 (2.26)
42.6 (2.66)
21.6
15.6
0.4
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-0.7
21.3
14.9
-0.4
21.6
18.4
-0.3
138-172
(20-25)
90-110
(13-16)
138-172
(20-25)
90-110
(13-16)
138-172
(20-25)
90-110
(13-16)
138-172
(20-25)
90-110
(13-16)
>90
>90
>90
>90
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Capital Investment: HFC versus non-HFC
Why are HFC-245fa and HBA-2 blowing agents low capital investment?
• They are non-flammable  none to limited capital requirement
– Low risk – technology, workplace safety, environmental
• HCFC-141b PUR equipment  little to no equipment modifications required
• Both are liquid blowing agents with moderate vapour pressure
– May require storage vessel up-grade  low capital investment
• HFC-245fa conversion from HCFC-141b in US: Cost ≈ Minor
Why are Non-HFC (hydrocarbon & methyl formate) blowing agents challenging?
• Generally flammable  significant investment in flammability mitigation
– Blending operations; foaming equipment; storage vessels
– Consequences of miss-operations  inherent risk of fire / explosions
• Factory emissions  probable ground level smog formation
• Non-HFC PUR foams typically exhibit deficiency in insulation performance
• Non-HFC conversion in US: Cost ≈ $500 K USD to $ 5 M+ USD
(small asset)
(refrigerator factory)
HBA-2 is a LOW capital investment, near ‘drop-in’ transition from HFC-245fa
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Operational Cost: Implications
Cost Relative to HCFC-141b
Operational Cost: Energy Efficiency Recovery w/ non-HFC PUR
2
1.5
1
0.5
0
HFC
PUR Cost
non-HFC: Panels
non-HFC: Refrigerators
Cost of Energy Efficiency Restoration: Panels & Refrigerators
• HFC = lowest total cost path to high performance for regulatory compliance
• Non-HFC solutions have inherent energy efficiency penalty
– Cost to restore energy efficiency: panels – low cost; refrigerators – high cost
• Non-HFC solutions exhibit deficiencies in density, dimensional stability, LTTR*
* LTTR: Long Term Thermal Resistance
Non-HFC PUR requires additional costs to achieve equal performance
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HFC Solutions Summary
• ODS and GWP reduction is imperative on a global basis
• HFC solutions: thru HFC-245fa ‘bridge’ route . . .
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Provides a balanced, technology neutral / low capital investment pathway
Positions the industry for future HBA-2 adoption
HFC-245fa and HBA-2 do not contribute to ground level smog formation
Non-flammable: inherently safer utilisation in applications
• HFC’s allow for orderly industrial transition:
– Frees up ODS rights under an ODS Cap
– Accommodates industrial and economy growth
• HCFC-141b / HFC blends  possible attractive solution
– ODS reduction on an interim basis
– Energy efficiency neutral with respect to operational costs
– Economic valuation: low capital investment & raw materials cost reduction
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Blowing Agent Commercialization Status
• HFC-245fa
– Registered for use globally
– Commercially available globally
– Commercial manufacturing site: 2002 in U.S.
• 1234ze(E)
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U.S.: SNAP listed / PMN pending EPA approval
EU: Registered under REACH (article 24): 1000+ tonnes/year
Japan: Registration complete
Commercial capacity: 2008 in U.S.
Commercialized in EU and Japan
• HBA-2
– Toxicity assessment underway: completion 1Q 2011
– Global notifications/registrations
• U.S.: SNAP / PMN applications are in progress
• EU: REACH inquiry stage
• Japan: Filed for compliance with Japan Chemical Substances Control Law
Environmental solutions have/will meet regulatory needs timing
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DISCLAIMER
Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind,
expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user
assumes all risks and liability for use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made
without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. The user should not
assume that all toxicity data and safety measures are indicated herein or that other measures may not be required.
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Specific Innovation Requiring Regulatory Approval
– Excellent Environmental / Physical / Economic Properties
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GWP of 7
ODP < 0.0005
Non-flammable
Atmospheric Life < 50 days
• Very Low POCP
• Compatibility (Plastics and Most Elastomers)
• Similar Economics to Current HFC
– Tremendous Potential as HFC / HCFC Replacement
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Low GWP Material Designed for “Traditional” Applications
Foam Blowing Agent: Insulation Performance 3-5% Better vs.HFC-245fa
Solvent: Exhibits Very Attractive Solvent Performance Properties
Refrigerant for Chillers: Applications Testing by Major OEMs
– Hurdle to Overcome: Lack of Environmental / Legal Certainty
• ODP Lower Than Many Non-regulated Chlorinated Solvents
– Methylene Chloride:
ODP: 0.0047
Atmospheric Life: ~ 180 days
– Perchloroethylene:
ODP: 0.006
Atmospheric Life: ~ 110 days
No Certainty in Status Quo – Threshold Value Needed
India: February 2011